Methods &amp; systems for modular buildings

ABSTRACT

Systems and methods providing a modular building that is self-contained within a standard shipping container, wherein the pre-fabricated panel wall components are easily assembled to form a predetermined structure using a cam-based component connector. system that provides for mating, dual-track alignment and locking of the modular panels with each other along their adjoining seams

CROSS-REFERENCE TO RELATED APPLICATION

The present invention claims priority from U.S. provisional patentapplication 61/063,191 filed Feb 2, 2008, which is incorporated hereinby reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to modular building systems andmethods, and more particularly, to modular building systems and methodsfor containerized shipment thereof.

2. Description of the Prior Art

Modular buildings and components used in making them are known in theart. By way of example, prefabricated housing components, including wallpanels are known. However, energy losses most commonly occur in the seamor joint regions of structures, including prefabricated buildings andmodular structural components. Additionally, while prefabricated panelsand other components are known in the art, they are not packaged orprovided for quick and easy assembly to form a predetermined completedstructure that also provides for an energy efficient structure that isalso stable and reliable, i.e., able to withstand the natural elementsincluding storm conditions.

One example of commercially available modular building components isfound at http://aguentium.com/housing.htm.

None of the prior art addresses the longstanding need for stable, energyefficient modular building structures, including kits for installingsame, in particular having structurally locked wall panel componentsthat are aligned with a mating double rail track edge system. Thus thereremains a need for energy efficient and stable modular building systemsand methods for installing them, including providing containerizedpackaging to facilitate shipment, assembly and installation of thebuilding.

SUMMARY OF THE INVENTION

The present invention provides modular building systems and methods forshipment and installation of them.

One aspect of the present invention is to provide systems and methodsfor a modular building that is self-contained within a standard shippingcontainer, wherein the pre-fabricated panel wall components are easilyassembled to form a predetermined structure using a cam-based componentconnector system that provides for mating, dual-track alignment andlocking of the modular panels with each other along their adjoiningseams. Another aspect of the present invention is to provide a modularbuilding system for a portable, storable complete building kit whereinthe kit is completely optimally provided within a standard shippingcontainer. Still another aspect of the present invention is to provide amodular building system with prefabricated composite wall panels thatinclude conduits provided within the panels. Methods for installation ofthe modular building system are also considered aspects of the presentinvention. These and other aspects of the present invention will becomeapparent to those skilled in the art after a reading of the followingdescription of the preferred embodiment when considered with thedrawings, as they support the claimed invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-8 illustrate various views of the invention.

FIG. 1 shows a perspective view of a container for housing the modularbuilding system according to one embodiment of the present invention.

FIG. 2 illustrates a perspective view of stacked contents of the kit formodular building structures of the present invention, configured to fitwithin the container shown in FIG. 1.

FIG. 3 shows a loaded container of FIG. 1 with the components of FIG. 2.

FIG. 4 illustrates a perspective view of a partially assembled modularbuilding structure.

FIG. 5 shows a perspective view of a completed modular building from thepartially completed illustration of FIG. 4.

FIG. 6 illustrates several related views; in FIG. 6A a top view of twoedges of modular wall panels having mating double railing for alignmentand locking mechanism; FIG. 6B illustrates an end perspective viewillustrating the parallel spaced apart double track or railing system;FIG. 6C illustrates a side view and cut-away of joined panel edges withthe interlocking cam-based locking mechanism. While the interlocking cammechanism is desirable for providing additional securement at the jointsbetween two panels, it is not a requirement for some level of stability.

FIG. 7 illustrates a top view of a corner wall panel modular componentwith seamless corner.

FIG. 8 illustrates several perspective views of the modular buildingcomponents in various stages of installation.

DETAILED DESCRIPTION

In the following description, like reference characters designate likeor corresponding parts throughout the several views. Also in thefollowing description, it is to be understood that such terms as“forward,” “rearward,” “front,” “back,” “right,” “left,” “upwardly,”“downwardly,” and the like are words of convenience and are not to beconstrued as limiting terms.

The present invention provides systems and methods for a modularbuilding that is self-contained within a standard shipping container,wherein the pre-fabricated panel wall components are easily assembled toform a predetermined structure using a cam-based component connectorsystem. Another aspect of the present invention is to provide a modularbuilding system for a portable, storable complete building kit whereinthe kit is completely optimally provided within a standard shippingcontainer. The present invention also provides a modular building systemwith prefabricated composite wall panels that include conduits providedwithin the panels; these conduits may optionally be pre-wired. Methodsfor installation of the modular building system include the steps ofproviding a prefabricated modular building kit having all components andinstructions for assembly optimally disposed within a standard shippingcontainer for portability and storage; removing the kit from theshipping container; assembling the modular housing by arranging andconnecting the composite wall panels, which may include conduits forelectrical and/or plumbing disposed within the interior section of thecomposite wall panels, including input/output openings for wiring, etc.

Referring now to the drawings in general, the illustrations are for thepurpose of describing a preferred embodiment of the invention and arenot intended to limit the invention thereto. As best seen in thefigures, especially FIGS. 1-6, an illustration of a container forhousing a modular building kit is shown; in FIGS. 7-8, a modularbuilding materials are shown including interlocking pre-engineered andpre-insulated panels that are constructed and configured to be quicklyattached together by juxtapositioning their respective edges to form thewalls, roof, or floor of a structure.

FIG. 1 shows a perspective view of a container 10 for housing themodular building system according to one embodiment of the presentinvention. FIG. 2 illustrates a perspective view of stacked contents ofthe kit for modular building structures of the present invention,configured to fit within the container shown in FIG. 1; the contents ofthis illustration include furniture 1001, panel splines 1010, bedding &food prep supplies 1030, windows & doors 1040, exterior flashingmaterial 1020, kitchen core module 1050, tools & fasteners 1060, bathcore module 1070, power generator 1080, environmental equipment 1090,plumbing & electrical equipment 1100, additional supplies 1120, wallpanels 1128, gable end panels 1130, roof panels 1140, and roof panelsupport beams 1150. FIG. 3 shows a loaded container 12 of FIG. 1 withthe components of FIG. 2. FIG. 4 illustrates a perspective view of apartially assembled modular building structure 1180, including doorcomponent 28, wall panel edges 20, 22, wall panel face side 16, and backside 18, wall panel (generally referenced 14), joined edges or seam 24,roof panel 26. FIG. 5 shows a perspective view of a completed modularbuilding from the partially completed illustration of FIG. 4 including awindow unit 30. FIG. 6 illustrates several related views; in FIG. 6A atop view of two edges of modular wall panels having mating doublerailing 32 for alignment and locking mechanism 34 ; FIG. 6B illustratesan end perspective view illustrating the parallel spaced apart doubletrack or railing system 33; FIG. 6C illustrates a side view and cut-awayof joined panel edges with the interlocking cam-based locking mechanism(cam 36, locking arm 38, seam 40). FIG. 7 illustrates a top view of acorner wall panel modular component with seamless corner 42 withinsulation 19 a face side 16 and back side 18 of the wall panel, anddouble rail mating alignment components 32, 33. FIG. 8 illustratesseveral perspective views of the modular building components in variousstages of installation.

The structure size is predetermined before packaging, but ranges in sizefrom small to very large buildings, by way of example and notlimitation, such as an emergency shelter, a home or a command shelter oroffice. The size of the panels generally requires only two or threepersons to manually maneuver the panels for complete structure erection.The material of both the interior and the exterior siding of the panelsis selected based upon the needs of the customer and the environment,but in any case the panels are both insulated and portable. Preferably,the panels are super-insulated and portable to allow the builder to getunder roof and into a comfortable space in a very short period of time.

In one embodiment of the present invention, items such as electricaljunction boxes, conduit or radiant heating coils are preferably moldedinside of the panels, constructed and configured in such a way on siteas to add additional value to the structure. Beneficially, the structureis assembled quickly and may be pre-fitted with conduit (as delivered tothe site in the self-contained kit, preferably in a shipping container),to allow for quick installation of a fully-equipped building, includingelectrical functionality. Doors and windows are also preferablydelivered with and included in the building kit. Preferably, openingsfor the windows and doors are pre-framed in the panels in a manner thatallows for rapid window and door installation on site, withoutadditional time or materials required for framing and installation. Roofbeam pockets are also preferably pre-set in the top of panels tofacilitate the placement of rafter or ridge beams to allow for thesupport of the insulated roof panels.

In a preferred embodiment, the entire system is packed as a complete kitwithin a cargo container or standard shipping container as illustratedin FIG. 1. This optimized packaging for using the container facilitatesthe delivery and storage of multiple containers in a central locationuntil such time as needed for rapid erection of a structure, for examplein the case of an unexpected natural disaster. This building kit alsopreferably includes a complete tool kit to facilitate complete assemblyof the structure; the building kit may also include items such as anelectric generator, limited fuel for the generator, a renewable powersource such as solar panels or wind turbines, water and basicnon-perishable foodstuffs, thereby providing for a complete emergencyshelter that can be occupied and used immediately upon delivery andinstallation, without requiring any separate tools, supplies, orequipment to be a fully-functioning facility or shelter. The containermay also include cabinets, sinks, toilets, showers and even furniturefor installation within the modular building to provide for immediateand also possibly long-term occupancy in the shelter. The cargocontainer could then be used as a secondary structure for storage ifleft on the site.

Advantageously, the panels of the present invention are the mostadvanced structurally insulated building panel on the market today. Forcorner panels they may be provided all flat panels so that they willstack tighter. The present invention provides a modular building systemfor creating an energy-efficient structure including: a multiplicity ofpre-fabricated panel wall components and roof components, each having aface side and a back side and four edges including a pair ofspaced-apart parallel tracks that run the length of at least twoopposite edges for aligning the edges together to form a seam, whereinthe components further include locking components for securedlyattaching the components together along the seams.

Also, methods for providing a modular building structure including thesteps of: providing a containerized kit wherein the kit is sized andconfigured to be enclosed by a housing and includes therewithin amodular building system further comprising a predetermined number ofmodular wall components, a roof system, and at least one door; providinginstructions for assembling the modular building system for forming acomplete building unit, including aligning the modular wall componentsalong their opposite edges via a double mating spaced apart rail thatextends along the length of the wall to provide an energy efficient seamwhen wall components are joined.

One application for the present invention includes a structure orbuilding for a command or support center after an emergency to beerected on a flat surface. Other applications include but are notlimited to medical center, school or residential structures.

In preferred embodiments of the kits for modular buildings, preferablyincluded with the modular panel components for assembling to form abasic structure are the following:

Panels in a pre-configured kit including window panels, door panels,corner panels, beam pocket panels and window(s) pre-set into at leastone panel; at least one door frame fitted to allow final site placementquickly and easily; at least one ventilation fan pre-installed in panel;and wherein the panels have at least some finishing on the face sidethat would be externally or outwardly facing upon assembly andinstallation for the building structure, by way of example and notlimitation the face side finish includes a pre-finished exterior sidingsuch as commercially offered by Hardi Panel or LP SmartSide; a pluralityof structural members for supporting roof structure including a modularbox beam with joints secured by pins; at least one composite sill plateand secondary base plate with flashing for foundation; tools requiredfor structure assembly including panel cam-locks, sealant foam, foamapplicators, etc.; instructions, plans, and figures illustratingassembly in at least one language or even multiple language(s) asrequired, preferably including figures showing step-wise assembly andinstallation, as well as an indication or listing of all the parts andcomponents within the kit and how they relate to each other; rigidflashing for the top roof ridge (at the junction of the two differentpanel slopes), roof lining material, finished roofing material, modularelectrical baseboard outlet kit; communications system or equipment(such as by way of example and not limitation, a communication systemfor satellite-based telecommunication of voice and/or data); scaffoldingif wall panels were greater than about 8 ft. in height; Universal PowerSupplies & filter (UPS) for sensitive electronic equipment; solar panels(PV or solar-thermal) for attachment or integration with select panels,preferably roof panels; FRP laminated panel interior (like for medicalor school application); at least one bathroom module including sink andtoilet, and preferably a shower unit.

Additionally, it is preferred to have equipment and/or appliancesincluded with the kit to provide a fully functioning building structurewith energy, heat and/or cooling, testing equipment, refrigeration,cleaning equipment, portable beds and/or bedding (in particular in thecase of a medical structure application), at least one generator withfuel storage tanks safe for long term storage (LP, LNG, etc.), a potablewater supply or container therefor (such as for about 250 gal of water),meals ready to eat (MRE) wherein the quantity depends upon userspecification, cooking equipment, such as portable camping-type ovens;matches or other flame source, a ladder, solar oven or solar-poweredcooking or heating equipment; water purification system for point-of-usewater treatment; water collection system (including but not limited torain collection), portable battery-powered and/or rechargeable lighting,computers and electronic equipment, etc.

Other optional supplemental items for inclusion in the kit mayselectively include the following: basic modular furniture (tables,chairs, filing cabinets, locked storage cabinets, etc.), First Aid Kits;portable transportation for personal use, such as all-terrain vehicles,motorized or manual, or bicycles (mountain bikes); surveillanceequipment.

Optional Extras may further include: additional consumable supplies,including but not limited to food, water, medical supplies, batteries,water filters or point-of-use purification equipment; medication orfirst aid supplies; bedding and clothing; protective gear specific topredetermined location, by way of example and not limitation, gas masks,impermeable gloves, hat, clothing, to protect from contamination ortoxic agents; rope, chainsaws, other tools.

Also, supplemental or specific power supply alternatives may beprovided, including by way of example and not limitation, a wind powergenerator, water power generator, solar power generating equipment, etc.

One application of the kits for modular buildings according to thepresent invention is to provide emergency shelter kits that would bedeliverable to a site or location in advance of or following anemergency situation, such as weather catastrophe, illness outbreak, ormay also be provided in advance of construction of larger buildings.While the present invention modular buildings formed from the kits andcomponents described herein are suitable for long-term use, they mayalso be used for temporary buildings or for limited time specific usebuildings. As such, the containers housing the kits for modularbuildings preferably are rated and/or have a “storage life” where someitems like tool batteries, MREs, water, and other items having somepredetermined shelf life, would have to be replenished after apredetermined time, by way of example about 5 years. Replenishment kitsmay optionally be packaged for inclusion within the kit or separatelyand independently ordered periodically based on the number of containersoriginally ordered and not yet used.

Certain modifications and improvements will occur to those skilled inthe art upon a reading of the foregoing description. The above mentionedexamples are provided to serve the purpose of clarifying the aspects ofthe invention and it will be apparent to one skilled in the art thatthey do not serve to limit the scope of the invention. All modificationsand improvements have been deleted herein for the sake of concisenessand readability but are properly within the scope of the presentinvention.

1. A modular building system for creating an energy-efficient structurecomprising: a multiplicity of pre-fabricated panel wall components androof components, each having a face side and a back side and four edgesincluding a pair of spaced-apart parallel tracks that run the length ofat least two opposite edges for aligning the edges together to form aseam, wherein the components further include locking components forsecuredly attaching the components together along the seams.
 2. Thesystem of claim 1, wherein the seams are vertical.
 3. The system ofclaim 1, wherein the locking components are embedded mechanical lockingcomponents.
 4. The system of claim 1, wherein the mechanical lockingcomponents include mating, dual-track alignment seams and a cam-basedconnector that extends between a first position and a second position,wherein the at least two edges are first aligned by the mating,dual-track alignment seams when the cam-based connector is in the firstposition (unlocked) and then the connector is moved to the secondposition to lock the wall components together, thereby providing anenergy efficient seam where the components are connected, aligned, andlocked together.
 5. The system of claim 1, wherein the wall componentsare attachable by aligning the tracks from two wall components with eachother and locking them together mechanically.
 6. The system of claim 1,wherein the multiplicity of components are assembled at mating edgesthat provide for aligned and locked seams.
 7. The system of claim 1,further including special wall components that are shaped to providecorners for a rectangular structure, wherein corners have no seam orjoint.
 8. The system of claim 1, wherein the modular wall panelcomponents include insulation between the face side and the back side.9. The system of claim 1, wherein the modular wall panel components havean energy efficiency rating for energy star ratings.
 10. The system ofclaim 1, wherein the system further includes optional componentsselected from the group consisting of at least one window, electricalconduit, electrical wiring, switches, outlets, lighting fixtures,plumbing, plumbing elements, and combinations thereof.
 11. The system ofclaim 1, further including appliances or equipment that are operableafter installation in the building after the components have beenassembled together to form the building.
 12. A method for providing amodular building structure comprising the steps of: providing acontainerized kit wherein the kit is sized and configured to be enclosedby a housing and includes therewithin a modular building system furthercomprising a predetermined number of modular wall components, a roofsystem, and at least one door; providing instructions for assembling themodular building system for forming a complete building unit, includingaligning the modular wall components along their opposite edges via adouble mating spaced apart rail that extends along the length of thewall to provide an energy efficient seam when wall components arejoined.
 13. The method of claim 12, wherein the system further includesoptional components selected from the group consisting of at least onewindow, electrical conduit, electrical wiring, switches, outlets,lighting fixtures, plumbing, plumbing elements, and combinationsthereof.
 14. A method for installing a modular building structure,comprising the steps of:
 14. The method of claim 12, wherein the systemfurther includes appliances or equipment that are operable afterinstallation in the building after the components have been assembledtogether to form the building.
 15. The method of claim 12, wherein thepanels are lockable to form a predetermined structure using a cam-basedcomponent connector system that provides for mating, dual-trackalignment and locking of the modular panels with each other along theiradjoining seams.